By Mike Ditton, Evoqua Water Technologies
In large systems, the dissipation of process or ambient heat generated by manufacturing,
power generation and food processors often is accomplished by cooling towers. These
structures facilitate the transfer of heat through the use of water.
For many cooling tower systems, fine suspended solids in the cooling water are the cause of
inefficacies. In addition to decreasing heat transfer efficiency, the suspended solids also can
pose a health risk. These fine solids originate from the facility's process, piping, atmosphere
or makeup water source, or from the system's internal biological growth
During the cooling process, the cooling water absorbs
large volumes of airborne particulate, acting as an air
scrubber and filtering the surrounding air. With time,
these fine particles can build up and settle within the
system, adversely affecting cooling performance while
reducing the life of wetted subcomponents.
Your Heat Exchanger
is Only as Reliable
as its Components
Typically, 85 percent of the suspended solids in cooling
water and hot water loops are smaller than 5 microns in
size. Scientific studies have shown that these fine
particles tend to be the adherent contaminants causing
fouling of the cooling tower water, chilled water and
heat exchangers. Such contamination reduces cooling
system efficiency. High volumes of fine suspended
particles will not always be eliminated solely with the
use of a chemical program; therefore, fine filtration is an
important addition5 Trends Driving the Need for Cleaner
Water in Cooling Applications
5. Requirements for the creation of risk-assessment programs.
The Cost of Working with Dirty Water
The presence of fine suspended and dissolved solids, in high volumes, can be harmful to a
cooling tower and water loop, affecting the performance of the entire system. Fine
particulates under 5 microns in size aid in contributing to the following challenges:
‘+ Component clogging, This causes irregular distribution of the water across the
cooling tower.
‘+ Heat transfer inefficiencies. This require increased energy and water, dr
upward.
+ Scaling, fouling and bacterial growth such as Legionella. These cause quick
degradation of components, resulting in early replacement, increased maintenance
costs and health concerns.
+ Unscheduled shutdowns and cleaning. These lead to increased operating costs.
+ Early replacement of components (valves, pumps or heat exchangers, for instance).
+ Increased and accelerated corrosion.
ng coststestes
High eticincy removal of tn parts and suspended solids can help reduce maintenance and operating costs.
Ahigh efficiency media filtration system can optimize water treatment efforts in several
ways. Traditional sand filters lack fine-filtration capabilities and have relatively low capacities.
High efficiency media filters offer submicron performance, higher flow, a compact
design/footprint, automated operation and a low cost of operation
High Efficiency Submicron Performance. The effectiveness of a high efficiency media
filtration system lies in its use of microsand media coupled with crossflow filtration. These
features allow the filters to capture particles under 1 micron in size,
Higher Flow. Crossflow technology enables optimization of the media bed. This improves
filtration capacity and allows the design of a horizontal vessel. For instance, with a single 36”
vessel, the horizontal design is capable of treating a flow of up to 1,090 gal/min. The filtration
velocity through the media bed is faster than sand filters at 25 gal/min/ft? (60 m/hr) while
delivering high water quality.
Lower Cost of Operation. An important
consideration for any filtration system is the
overall operating cost. This type of high
efficiency filtration system potentially
reduces operating costs in several ways. It
can:
‘+ Minimize water consumption by the
filter. The filter requires up to 50
percent less water during backwash
when compared to traditional
multimedia filtration systems.
+ Achieve energy savings in heat
transfer applications by helping
prevent the formation of sediment
and biofilm. This leads to greater heat
exchanger efficiency.
+ Improve the effectiveness of the
chemical treatment by reducing total
suspended solids
+ Reduce maintenance costs. A high
efficiency filtration system requires
little human intervention with few -Averticaly oriented, stacked system can double the filtration capacity
maintenance tasks. within th same equipment footprint.
Ec)
Automated Operation. 4 high efficiency filtration systern provides an automated experience
along with maintenance reminders and a user-friendly interface. These features help
simplify operating and maintaining the system.
‘Compact Footprint. The use of microsand media yields a filtration system that requires less
media. This allows the system to achieve high levels of efficiency with a smaller footprint,
(With some designs, the filtration system is up to 80 percent smaller and lighter in weight
than multimedia filters) In addition, some designs allow for customization to better suit the
aplication. One such customization is a vertically stacked svstem. which increases thefiltration capacity within the same footprint. A lightweight, compact filter design also
provides shipping savings and can reduce on-site infrastructure costs.
High eicieny media filters offer submicron performance, high ow, a compact design and automated operation.
In conclusion, high efficiency removal of fine particles and suspended solids can reduce
maintenance and operating costs while improving the bottom line. A water filtration system
should help meet growing production goals and water reuse objectives, PC
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Mike Ditton isthe senior product manager with Evoqua Water Technologies. The Pttsburgh-based company can be reached at 724-112-
0044,